Conventional manufacturing methods are sub-optimal for nano-composites fabrication. Inhomogeneous dispersion of the secondary phase and scalability issues are the main issues. This work focuses on an innovative method where the reinforcement is formed insitu in the melt. It involves the reaction of the molten aluminum with a nitrogen-bearing gas injected through the melt at around 1273 K. AlN particles are expected to form through this in situ reaction. A model has been developed to predict the

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... amount of reinforced phase. Experiments have been carried out to confirm the feasibility of the process and the mechanism of AlN formation discussed. The detrimental effect of oxygen in the melt which hinders the nitridation reaction has been proved. The effect of process times and the addition of alloying elements (Mg and Si) have also been investigated. iii Acknowledgments First of all, I really would like to thank my advisor, Professor Diran Apelian. He taught me how to approach scientific research. He provided me with a different look of the world and guided me through the issues that I encountered during my investigation. He is my model not only as an engineer, but as a fulfilled and illuminated person. He supported me in several times and never left me alone. I want to thank Professor Makhlouf M. Makhlouf for the incredible help in my experiments and for the additional value that his experience has provided to my work. His continuous drive towards new ideas has inspired my research.